Overtufting method
An overtufting machine/method provides additional yarn per area in an area of design than in areas lacking the overtufted design. Specifically, for many embodiments, a carpet is first tufted, and then run past an overtufting station which preferably moves in a lateral direction relative to the direction of feed to direct at least one needle through the carpet in at least one selectable height option. Rails are preferably used to shuttle the needle supported by a head on at least one carriage to shuttle along the rail(s).
This application claims the benefit of U.S. Provisional Patent Application No. 61/761,482 filed Feb. 6, 2013, 61/762,458 filed Feb. 8, 2013, 61/766,968 filed Feb. 20, 2013, and 61/833,560 filed Jun. 11, 2013, all of which are incorporated by reference in their entirety.
FIELD OF THE INVENTIONThe present invention relates to a tufting operation and particularly a tufting operations such as tufting through a pre-tufted carpet to provide a design feature therethrough, and in many embodiments the area of the design feature will have a higher stitch count than portions not having the design feature, and still other embodiments envision cross-tufting, i.e., tufting in a lateral direction relative to the direction of feed, or possibly simultaneously with a direction of feed for some embodiments.
BACKGROUND OF THE INVENTIONPatents such as U.S. Pat. Nos. 7,218,987 and 8,225,727 allow creative images to be tufted into carpet backing. Other devices similar to those shown in U.S. Pat. Nos. 7,814,850 and 7,478,605 are also known for such use. While these are all excellent devices for slow speed operation, the applicant desires to rely on a machine and methodology which will improve his prior art techniques and machines.
Also, mending guns have been available to the carpet industry to add stitches of carpet where missed during making carpet. These guns typically have a single needle and some may have yarn feed systems to allow for multiple pile heights such as shown and described in U.S. Pat. No. 6,260,493, incorporated herein by reference. Other mending guns may have a cutting attachment to be able to cut inserted yarn such as shown and described in U.S. Pat. No. 3,645,249 incorporated herein by reference. However, these guns are designed to be used to tuft through backing (and not the pre-tufted carpet) to fill in where tufting machines have not already introduced yarn.
SUMMARY OF THE INVENTIONIt is a present object of many embodiments of the present invention to provide an tufting machine and/or methodology, particularly one suited to overtuft through a pretufted carpet with design elements that are believed to be somewhat novel in approach.
Specifically, a roll which is preferably could be a pretufted roll of carpet, but could also be a roll of yet-to-be tufted backing for at least a few embodiments, may be fed through the tufting machine such as from a supply roll to a finished roll. Some embodiments can provide prior art tufting through backing and then a second station for overtufting. A presently preferred embodiment of the present invention provides the input roll to a tufting machine which tufts through a roll of pre-tufted carpet in many embodiments (“carpet material”). Feed and/or processed rolls may be servo and/or otherwise controlled to feed in the direction of feed from the input roll to the processed or finished roll in a direction of tuft. Other embodiments may operate on a plotter style system with or without rolls. And still other systems may not use rolls at all.
Intermediate the input roll and the processed roll may preferably at least one tufting station having a head supported by a frame. The head may be comprised of a plurality of needles, possibly 24 or other number, whereby the needles may engage the carpet material as it passes from the input roll to the processed roll. The tufting head may be elevationally adjustable relative to the carpet material when tufting and/or at least some, if not any of individual needles, may be elevationally positionable to provide for pile height adjustment, possibly on the fly. Pile height may also be adjusted/adjustable with a yarn feeder mechanism or otherwise to the needle, such as can be found with needle mending gun technology. Cutters may be provided to cut the yarn from individual needs. Also the needles may be arranged in an array other than 1×24, such as 6×4 or any other array. Some of the needles are preferably aligned linearly with a direction of feed for many embodiments. Other needles may be aligned in the lateral direction (perpendicular to the direction of feed). Still other embodiments may provide an array which is not aligned with one or both of the direction of feed or the lateral direction.
A second tufting station may be located before the first station (i.e., closer to the input roll). The second tufting station may tuft backing to provide pre-tufted carpet to the first station for at least some embodiments.
Furthermore, the tufting head may preferably be laterally moveable relative to the carpet material and/or frame so that cross tufting can be accomplished as well as possibly tufting into or away from a direction feed from the input to the processed rolls, or even angularly tufted such as diagonal, curved or other configurations. The carpet may also be moveable relative to tufting heads for some embodiments. Bands of material may be tufted laterally (cross tufting) or even obliquely (at an acute angle relative to lateral tufting) for some embodiments. It can be quickly seen that with x-y capability, angles, curves, or virtually any tufting pattern could be established. Furthermore, in some embodiments, the individual needles, whether individually and/or collectively may be adjustable in width and/or elevation amongst themselves on the tufting head attributing to additional effect. In some embodiments needle spacing may be automatedly controllable so that the at least assisting in spacing between adjacent needles could be adjusted possibly even on the fly. Elevational adjustment could also be adjustable, as discussed above.
One or more tufting head(s) may also be moveable into the direction of the feed or away from the direction of the feed such as by having rollers on a carriage and/or frame portion which may also be controlled by servo motors and/or other mechanisms by their adjustment mechanisms. Although cooperating hook and/or knife feet(s) may cooperate with head(s) for at least some embodiments, presently preferred embodiments may operate more like a mending gun for each needle or otherwise and can produce multiple pile heights without a cooperating foot with hook and/or knife feet. Furthermore, as would be understood by those of ordinary skill in the art, not only is x-y and z adjustability provided for one or more needles within the tufting head, individual needles may also be provided with various adjustability in accordance with the sophistication of the computer program and/or equipment controlling the tufting operation. Furthermore, multiple heads may be used in parallel or may be separately controllable on the tufting machine in various embodiments. While operation like a tufting machine can occur, the applicant ran a mending gun across a twelve foot section of pre-tufted carpet in about 90 seconds to show proof of concept that the mending gun could drive the needle consistently through pre-tufted carpet. Plotter style constructions could also be employed with this technology as well as other machines that could support one or more heads overtufting designs through pre-tufted carpet.
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
Roll 12 has been tufted in accordance with common tufting techniques as are widely known in the art. Specifically, a pre-determined number of stitches are preferably tufted per distance, such as per inch like 10 or 12. Furthermore the gage (or spacing between) between adjacent needles is normally determined by the tufting machine utilized. Accordingly for a set stitch count per inch, a relatively uniform pattern can be achieved, such as 10×10 per inch, 10×12 per inch, etc.
Some embodiments do not want or specify uniformity at the upper surface. Four yarns might be directed through one needle, while two yarns might be directed through adjacent needles to provide a couroroy type pattern of loops, possibly either with, or without varying pile height.
One or more tufting head(s) 16,18 may be mounted on one or more carriages 20,22 on one or more rails 24,26 or other appropriate structure for lateral movement in the directions 28 shown in
Rolls 12,14 could also be a portion of a tufting machine intermediate to or in conjunction with one or more carriages 20,22 could be directed. Of course, for even more custom looking work, one or more hand held heads 16,18 could be employed.
Computer 34 could preferably control not only lateral movement of the heads 16,18, for some embodiments, but also other movements which will be described below. Movements of the finished roll 12 relative to input roll 14 can be controlled by servo motors 36,38 and/or other mechanism so that movement into or away from the direction of feed 40 may be accomplished such as controlled by computer 34 or other device. The reverse direction of feed may also be accomplished with one or more servo motors 36,38 and/or other mechanism as would also be understood by those of ordinary skill in the art. The lateral direction 28 is perpendicular to the direction of feed 40. Other embodiments may use a plotter style construction and/or other constructions possibly without rolls 12,14. Some embodiments may not have computers 34 moving one or more heads 16,18. Instead, heads 16,18, preferably, but not always mounted on carriages 20,22, could be pushed by an operator across the input roll 14, or in a desired pattern relative to the input roll 14.
Meanwhile, with reference to
However, many embodiments will move needles as will be described below with reference to
It is also possible that tufting head 16,18 may be moved to proceed in or away from the direction of feed such as by moving along track 56 as may be directed by hand, one or more servo motors 58,60 or other device as shown in
As can be seen in
Needles 302 may be able to deliver multiple pile height such as high loops 304 or low loops 306 or even loops at or below the level of pre-tufted loops 308 as seen in
Adjacent needle assemblies 74,76 can be moved or adjusted along track 88 to desired locations such as by ½ inch locations and then secured in place such as with locks 90, etc. Alternatively, needle positions may be moved on the fly for some embodiments such as with servo motors 92,94 or other devices moving locators 96,98 in needle assemblies 74,76 as would be understood by one of ordinary skill in the art with reference to
As may be understood from
As may be understood with reference to
Tip shearing can take place using various equipment known in the art. Input roll 406 is directing product to output roll 410 in direction 408. One or more shears 402,404 may cut at various heights and positions as desired depending on the product to be made. For instance the pattern of
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
Claims
1. An overtufting method comprising the steps of:
- a) providing a pre-tufted carpet;
- b) at least selectively feeding the pre-tufted carpet in a direction of feed with a feeder;
- c) directing a first head having at least one needle fed with at least one yarn laterally to the direction of feed while overtufting at least a portion of a design element into the pre-tufted carpet whereby there are more tufts per area where overtufted than in portions not having at least a portion of a design element overtufted therein;
- wherein while performing the overtufting step laterally, simultaneously moving the first head in a direction of feed.
2. The overtufting method of claim 1 wherein while feeding the pre-tufted carpet in the direction of feed, rolling the pre-tufted carpet in the direction of feed.
3. The overtufting method of claim 1 wherein the step of directing the first head, simultaneously feeding multiple yarns through the at least one needle.
4. An overtufting method comprising the steps of:
- a) providing a pre-tufted carpet;
- b) at least selectively feeding the pre-tufted carpet in a direction of feed with a feeder;
- c) directing a first head having at least one needle fed with at least one yarn laterally to the direction of feed while overtufting at least a portion of a design element into the pre-tufted carpet whereby there are more tufts per area where overtufted than in portions not having at least a portion of a design element overtufted therein;
- wherein the first head is mounted on a rail and is constrained to be directed linearly at least partially in the lateral direction.
5. The overtufting method of claim 4 wherein the first head moves linearly in the lateral direction perpendicular to the direction of feed.
6. An overtufting method comprising the steps of:
- a) providing a pre-tufted carpet;
- b) at least selectively feeding the pre-tufted carpet in a direction of feed with a feeder;
- c) directing a first head having at least one needle fed with at least one yarn laterally to the direction of feed while overtufting at least a portion of a design element into the pre-tufted carpet whereby there are more tufts per area where overtufted than in portions not having at least a portion of a design element overtufted therein;
- wherein the first head is mounted a first carriage operably coupled to a rail, said carriage moving linearly along the rail in the directing step.
7. The overtufting method of claim 6 further comprising a second carriage operably coupled to the rail and spaced from the first carriage supporting a second head, wherein the directing step comprises overtufting at least a portion of the design element with the second head.
8. The overtufting method of claim 4 wherein the at least one needle is one of a plurality of needles oriented in a line along the lateral direction.
9. The overtufting method of claim 6 wherein the at least one needles is one of an array of needles.
10. The overtufting method of claim 4 wherein the feeding step is facilitated by providing the pre-tufted carpets on rolls, and further comprising the step of shifting the rolls laterally while performing the tufting step.
11. The overtufting method of claim 4 further comprising a computer, said computer controlling the movement of the at least one needle during the tufting step.
12. The overtufting method of claim 11 wherein said computer controls the movement of the first head during the tufting step.
13. The overtufting method of claim 11 wherein said computer controls the feeding of the pre-tufted carpet for the feeding step.
14. The overtufting method of claim 11 wherein the computer controls a level of elevation of the needles during the tufting step.
15. The overtufting method of claim 14 wherein the computer controls the level of elevation between at least a high and a low loop during the tufting step.
16. The overtufting method of claim 6 further comprising the step of tip shearing after overtufting.
17. An overtufting method comprising the steps of:
- a) providing a pre-tufted carpet;
- b) automatedly under the direction of a computer, directing a first head having at least one needle fed with at least one yarn laterally to the direction of feed while overtufting at least a portion of a design element into the pre-tufted carpet whereby there are more tufts per area where overtufted than in portions not having at least a portion of a design element overtufted therein;
- wherein the first head is operably coupled to a rail and wherein the directing step further comprises directing the first head linearly along the rail.
18. The method of claim 17 further comprising the step of at least selectively feeding the pre-tufted carpet in a direction of feed with a feeder.
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Type: Grant
Filed: Jan 7, 2014
Date of Patent: Dec 6, 2016
Inventor: Robert S. Weiner (Atlanta, GA)
Primary Examiner: Danny Worrell
Application Number: 14/149,160
International Classification: D05C 15/14 (20060101); D05C 15/10 (20060101); D05C 15/24 (20060101); D05C 15/30 (20060101);